Food product including fully or partially cooked egg

ABSTRACT

A food product involving an integral combination of an egg layer and an edible, grain-based solid substrate can be provided by a method that involves providing a precursor product which then is heated to provide the food product. The precursor product can be provided by introducing an egg mixture to a primary surface of the edible solid substrate. The heating of the precursor converts the egg mixture into the at least partially cooked egg layer of the food product.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a division of U.S. patent application Ser. No.15/588,672, filed 7 May 2017 and presently pending, which is acontinuation of U.S. patent application Ser. No. 13/839,852, filed 15Mar. 2013 and now issued as U.S. Pat. No. 9,642,383, the disclosures ofwhich are incorporated herein by reference.

BACKGROUND INFORMATION

Large portions of society continue to experience an increase in the paceof daily life. That quickened pace has been accompanied by increases inthe appreciation of and demand for convenience, particularly inconnection with food.

The importance of convenience can be seen in the growth in fast foodrestaurants, made-to-order vendors, and ready-to-eat frozen andrefrigerated foods. These trends have been particularly pronounced inconnection with food items commonly associated with breakfast, many ofwhich include some type of cooked egg product.

Interest in and demand for protein-rich foods also continues to growand, at least in connection with egg-origin protein, this intersectswith the increased demand for convenience discussed above.

Probably in response to these trends, multitudes of bread-eggcombinations have been made available. In these, whole eggs and eggcomponents (e.g., egg white only) have been prepared in a variety offorms including fried, scrambled, Benedict, omelet, etc., while breadproducts have included muffins, bagels, toasted or untoasted bread,rolls, tortillas, etc.

In addition to made-to-order products using fresh ingredients, vendorshave become comfortable with offering sandwich-like constructions thatare wholly or partially made elsewhere. For example, a fast foodrestaurateur might purchase a pre-made egg-based sandwich and merelyheat it prior to serving or, more commonly, fully heat a partiallycooked egg product for assembly with a bread product. In the home,made-to-order and ready-to-heat products are most common, with themiddle ground option (partially cooked, ready-to-assemble) being lesscommon.

Bread-egg combinations are not without drawbacks, of course. Forexample, where the egg component of the combination is in aBenedict-type form, it can fall out from between the top and bottombread components. Also, because of the nature of a sandwichconstruction, the ratio of protein-to-carbohydrate can be relativelylow.

A sandwich-type construction that increases the protein-to-carbohydrateratio and eliminates the possibility of spills while, at the same time,maintains the advantages of quick preparation and ease of handling hassignificant commercial value.

SUMMARY

Hereinafter is described a method of making a food product that is easyto handle, can be prepared quickly and easily, and has ahigher-than-usual ratio of protein-to-carbohydrate.

The resulting food product can be analogized to an open-faced eggsandwich with one important proviso, specifically, the egg-basedcomponent of the sandwich is integral with the bread component, whicheliminates the possibility that the two components can become separated,e.g., the egg-based component does not fall off or out of thebread-based component.

The food product involves an integral combination of an egg layer thatis at least partially cooked with an edible, grain-based solidsubstrate. This food product can be provided by a method that involvesproviding a precursor product which then is heated to provide the foodproduct. The precursor product can be provided by introducing an eggmixture to a primary surface of the edible solid substrate. The heatingof the precursor converts the egg mixture into the at least partiallycooked egg layer of the food product.

The egg mixture can be introduced to the primary surface of the ediblesolid substrate in at least two different ways. One such way involvesdepositing the egg mixture directly on the primary surface of theedible, grain-based solid substrate. Another way involves depositing theegg mixture into or onto a carrier, followed by applying a primarysurface of the edible solid substrate to the upper surface of thedeposited egg mixture.

The heating step of the process can involve baking, broiling,microwaving, steaming, hot air, combinations (e.g., any of a variety ofTurboChef™ ovens from TurboChef Technologies, Inc., of Carrollton,Tex.), and the like.

The resulting food product can be refrigerated or frozen for later use,either by an end consumer or by a vendor.

The food product, when ready for consumption (either immediately orafter reheating), is both easy to handle and convenient.

It also provides flexibility in sizing. The food product can be lesscaloric than the heretofore standard breakfast sandwich because one ofthe two bread layers has been eliminated. However, because each foodproduct includes an edible, grain-based solid substrate carrying anintegrated egg layer, two (or more) food products can be combined toform something that looks akin to the standard breakfast sandwich,albeit with cooked egg layers that are integral with and partiallyintegrated into the bread layers.

Other aspects will be apparent from the accompanying figures and themore detailed description that follows.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative configurations set forth in the description that followsare shown in the drawings, where similar numbers refer to similar partsor features. The figures are not necessarily to scale.

FIG. 1 is a side view of one embodiment of a food product according tothe present invention.

FIG. 2 is a sectional view taken along line 2-2 of FIG. 1.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The following description is provided to explain and exemplify theaforedescribed food product, particularly exemplary constructions andmethods of making. The appended claims define the inventions in whichexclusive rights are claimed, and they are not intended to be limited toparticular embodiments shown and described.

Food product 10 involves an integral combination of an egg layer 14 thatis at least partially cooked and an edible, grain-based solid substrate12.

Essentially any type of cereal can be used as the grain from whichedible substrate 12 is made, examples of which include, but are notlimited to, wheat (all types), buckwheat, oats, barley, sorghum, millet,maize, rye, quinoa, and rice. Certain other plant origin materials,e.g., soybeans, can be used in the manufacture of bread-like products,and these also can be used.

The particular form of edible solid substrate 12 also is not limiting.In FIGS. 1 and 2, edible solid substrate 12 is depicted as a half of abagel, but this is not limiting. Grains have been converted intomultitudes of edible products; as long as any of these products isamenable to being held in the hand and can support and integrallyconnect with the egg layer (discussed below), they can be used in thefood product of the present invention. Non-limiting examples includebread slices, bagels (sliced or unsliced), bagel thins, muffins, Englishmuffins, croutons, crackers, rolls and baguettes (sliced or unsliced),flatbreads (including tortillas), cornbread, and the like.

The thickness of edible solid substrate 12 generally ranges from ˜0.1 to˜1.0 inches, commonly from ˜0.2 to ˜0.8 inches, and typically from ˜0.3to ˜0.7 inches. The weight of edible solid substrate can vary widely butgenerally ranges from ˜0.5 to ˜5 ounces, commonly from ˜0.75 to ˜3ounces, and typically from ˜1 to ˜2.5 ounces.

If desired, edible solid substrate 12 can be toasted, browned, orotherwise heat treated prior to usage in the method described below.

Further, edible solid substrate 12 optionally can be soaked in, coatedwith or otherwise treated with any of a variety of spices such as salt,pepper, paprika, sesame seeds, granola, poppy seeds, coriander, cumin,curry powder, cinnamon, rosemary, and the like, any of a variety of oilsand oil-based spreads such as margarine, butter or any of a variety ofother types of dairy spreads, and any of a variety of glazes.

Egg layer 14 is at least partially cooked, meaning that it is cooked ata time/temperature combination that solidifies egg layer 14 sufficientlyto permit it to adhere to and become integral with a primary surface ofedible solid substrate 12. Typically, for a food product to be describedas pre-cooked, it must have reached a certain minimum temperature, e.g.,165° F. More details on the heating are provided below in connectionwith the discussion of the food product precursor.

Egg layer 14 can be provided from a flowable egg-containing composition.This composition can be provided from whole eggs, egg whites, egg yolks,synthetic eggs, synthetic egg whites, synthetic yolks, or a combinationof such ingredients.

Optionally but preferably, the flowable egg-containing composition alsocan contain any of a variety of solid taste and/or texture enhancers 16.These can include, but are not limited to, meats such as ham, bacon,sausage, steak, ground beef, poultry, pork, fish, and vegetarianversions of each, produce such as peppers, tomatoes, onions, carrots,parsley, pomes (including potatoes), corn, citrus fruits, and the like,and any of a variety of cheeses. These solid additives can be providedin whole form if sufficiently small but, in most case, will be providedin a parceled form such as diced, minced, shredded, cubed, cut, torn,mashed, julienned, and the like. In FIGS. 1 and 2, cheese and groundsausage are employed as solid taste and/or texture enhancers 16.

Other additives that can be included in the flowable egg-containingcomposition include, but are not limited to, any of a variety of spices(e.g., salt, pepper, paprika, coriander, cumin, curry powder, oregano,thyme, parsley, sage, rosemary, onion powder, etc.), preservatives suchas BHT, citric acid, EDTA, nisin, texture modifiers including any of avariety of starches, gums (e.g., xanthan and guar), enzymes,emulsifiers, baking soda, baking powder, lecithin, various caseinates,glucono delta-lactone, various phosphates, and the like.

The flowable egg-containing composition can be pre-heated prior tointroduction to edible solid substrate 12. This pre-heating can beaccomplished by kettle heaters, convection, conduction, microwaving,tube heating, RF, induction, etc., and preferably results in a flowableegg-containing composition at a temperature of from ˜90° to ˜150° F.

For egg layer 14 to become integral with, or integrally connected with,edible solid substrate 12, the latter preferably has sufficient surfaceroughness to permit the flowable egg-containing composition to partiallysoak into the substrate prior to solidifying at elevated temperature.Some materials useful as substrates, like sliced bagels and Englishmuffins, have substantial macroscopic roughness and, accordingly, arevery amenable to receiving the flowable egg-containing composition insuch a way so as to permit soaking and wicking of the flowableegg-containing composition beyond the very topmost layer of ediblesubstrate 12. Other materials potentially useful as substrates, e.g.,tortillas, appear much smoother but have significant microscopictexture, which often is sufficient to permit the flowable egg-containingcomposition to soak or wick into and become integral with the substrate.

The amount of flowable egg-containing composition to edible solidsubstrate 12 can vary widely but generally ranges from ˜0.5 to ˜6ounces, commonly from ˜0.75 to ˜5 ounces, typically from ˜1 to ˜4ounces, more typically from ˜1.25 to ˜3.5 ounces, and preferably from˜1.5 to ˜3 ounces. The thickness of the flowable egg-containingcomposition generally ranges from ˜0.1 to ˜1 inches, commonly from ˜0.2to ˜0.75 inches, and typically from ˜0.3 to ˜0.5 inches.

Introduction of the flowable egg-containing composition to edible solidsubstrate 12 results in provision of a precursor product which, uponheating, converts the flowable egg-containing composition into egg layer14, resulting in food product 10.

The precursor product can be provided by introducing the flowableegg-containing composition to a primary surface of edible solidsubstrate 12. The introduction of these two components can beaccomplished in at least two ways.

First, the flowable egg-containing composition can be applied to aprimary surface of edible solid substrate 12. The application can beaccomplished by any of a variety of techniques including, but notlimited to, pouring, extruding, curtain coating, knife coating, and thelike. Once the flowable egg-containing composition is applied, theprecursor product then can be heated. Where this process is performed ina commercial setting, a plurality of edible solid substrates can beprovided, optionally in an array, while being carried on a movingconveyance such as a belt. After flowable egg-containing composition isapplied to the substrates, the one or more precursor products areconveyed to an oven or other heating unit. A precursor product can beinverted after application of the flowable egg-containing composition tothe substrate, if desired; in such situations, preference can be givento those moving conveyances made from non-stick materials or treated soas to have low surface energy.

Second, the flowable egg-containing composition can be deposited onto abelt or into a mold prior to being covered, in whole or part, by aprimary surface of edible solid substrate 12. Deposition of the flowableegg-containing composition can be accomplished by any of a variety oftechniques including, but not limited to, pouring, extruding, curtaincoating, and the like. Once the deposited flowable egg-containingcomposition is covered by edible solid substrate 12, the resultingprecursor product then can be heated. Where this process is performed ina commercial setting, many molds can be filled and covered, and suchmolds optionally can be provided in an array. (If a belt is used, one ormore essentially continuous columns of deposited flowable egg-containingcomposition can be applied to the belt.) The belt and/or molds can beconveyed, to an oven or other heating unit.

The precursor product is heated so as to convert flowable egg-containingcomposition to egg layer 14. The heating can be accomplished byconvection, conduction, induction, microwaving, HTST, and preferablyraises the temperature of egg layer 14 to at least ˜100° F., morepreferably to at least ˜125° F., and most preferably to at least ˜150°F. for a time of at least ˜10 seconds. For certain applications,ensuring that egg layer 14 reaches a temperature of ˜145° to ˜165° F.for at least 20 seconds, at least 25 seconds, or at least 30 seconds canbe desirable. For taste and texture reasons, the heating step preferablydoes not occur at an oven temperature of more than ˜450° F., morepreferably no more than 400° F., and is not performed for more than ˜500seconds, commonly no more than ˜450 seconds, and typically no more than˜400 seconds.

Egg layer 14 can be partially or fully cooked. The term “partiallycooked” means that egg layer 14 has become integral with edible solidsubstrate 12 but its internal temperature has not reached 165° F., while“fully cooked” means that the internal temperature of egg layer 14 hasreached at least 165° F.

Upon heating, the precursor product is converted to food product 10where egg layer 14 is integral and interconnected with the upper portionof a primary surface of edible solid substrate 12. This feature is bestseen in FIG. 2, which is a cross-sectional view of food product 10 fromFIG. 1. To remove egg layer 14 from the primary surface of edible solidsubstrate 12 often results in cohesive failure of a portion of theedible solid substrate 12 as opposed to an adhesive failure between egglayer 14 and edible solid substrate 12.

Any of a variety of flavor enhancers can be added to food product 10.These include, but are not limited to cheese, artificial cheese, spices,artificial flavor solids, any of a variety of crunchy toppings (e.g.,bacon or bacon bits), and the like.

Food product 10 thus is provided in a convenient, easy-to-handle format.A consumer can be confident that egg layer 14 will not separate ordetach from edible solid substrate 12. Further, food product 10 includesone fewer edible substrate layer than a typical breakfast sandwich,thereby reducing the amount of carbohydrates and increasing theprotein-to-carbohydrate ratio ingested during consumption.

Unless food product 10 is to be consumed immediately after preparation,it can be introduced into packaging that permits both heating andcooling of its content. Preferably, food product 10 is cooled whencooking is complete. The amount of time necessary to cool a cooked foodproduct varies based on weight but, typically, refrigerated temperatures(e.g., ˜33° to ˜40° F.) can be reached in ˜10 to ˜20 minutes, andfreezer temperatures (e.g., 32° F. or below) can be reached in ˜15 to˜30 minutes using, for example, a batch or spiral chilling methods.

Similarly, food product 10 typically is packaged after cooking. Thenature of the cooling method(s) and the packaging employed typically isdriven by the expected shelf life and storage temperatures. For example,some food products might be intended to be used in ˜10 or fewer days,while others might be intended to be stored for up to several months.The former might be packaged using less costly materials and stored at˜33° to ˜40° F., while the latter might employ more robust packaging andbe stored at ˜10° to as low as about ˜10° F.

In situations where food product 10 is not consumed immediately afterpreparation and, instead, cooled and packaged, reheating prior toconsumption is contemplated. This can be accomplished in a number ofways including convection, conduction, induction, microwaving, hot air,etc., as long as the internal temperature of the egg layer reaches atleast ˜150°, commonly at least ˜160°, and typically at least ˜165° F.

The following table summarizes in list form the terms and phrases usedto identify suitable parts and materials.

TABLE 1 List of reference symbols Number Description 10 food product 12edible, grain-based solid substrate 14 egg layer 16 solid taste and/ortexture enhancer

The foregoing description has employed certain terms and phrases for thesake of brevity, clarity, and ease of understanding; no unnecessarylimitations are to be implied therefrom because such terms are used fordescriptive purposes and are intended to be broadly construed. Therelevant portion(s) of any patent or publication specifically mentionedin the foregoing description is or are incorporated herein by reference.

The foregoing configurations and methods have been presented by way ofexample only. Certain features of the described configurations andmethods may have been described in connection with only one or a fewsuch configurations or methods, but they should be considered as beinguseful in other such configurations or methods unless their structure oruse is incapable of adaptation for such additional use. Alsocontemplated are combinations of features described in isolation.

That which is claimed is:
 1. A method of making a food product thatcomprises an at least partially cooked egg layer and an edible,grain-based solid substrate, said method comprising: a) introducing fromabout 1.5 to about 3 ounces of a flowable egg-containing composition toa primary surface of said edible solid substrate, wherein the thicknessof said flowable egg-containing composition is from about 0.3 to about0.5 inches, said edible solid substrate being amenable to beinghandheld, b) allowing said flowable egg-containing composition to soakor wick beyond the topmost layer of said primary surface of said ediblesolid substrate so as to provide a food product precursor, and c)heating said food product precursor so as to convert said flowableegg-containing composition to said at least partially cooked egg layer,which is integrally connected with and bound to said substrate, therebyproviding said food product.
 2. The method of claim 1 further comprisingrepeating steps (a), (b) and (c) so as to provide a second food productand introducing said second food product to said food product so as toprovide a sandwich construction.
 3. The method of claim 1 wherein, atthe time of being introduced to said primary surface of said ediblesolid substrate, said flowable egg-containing composition is at atemperature of from about 90° to about 150° F.
 4. The method of claim 3wherein said flowable egg-containing composition has had its temperatureelevated via exposure to a kettle heater, convection, conduction,microwaving, tube heating, RF or induction heating.
 5. The method ofclaim 1 wherein said flowable egg-containing composition comprises oneor more solid additives.
 6. The method of claim 1 wherein said primarysurface of said edible solid substrate comprises macroscopic roughness.7. The method of claim 6 wherein said edible solid substrate is aportion of a bagel.
 8. The method of claim 6 wherein said edible solidsubstrate is a portion of an English muffin.
 9. The method of claim 1wherein said primary surface of said edible solid substrate comprisesmicroscopic roughness.
 10. The method of claim 9 wherein said ediblesolid substrate is a tortilla.
 11. The method of claim 1 furthercomprising packaging said food product and then cooling the resultingpackaged food product.
 12. The method of claim 1 wherein said heatingstep involves raising the internal temperature of said at leastpartially cooked egg layer to at least 165° F., thereby providing afully cooked egg layer.